US20030064164A1 - Apparatus and method for coating photoreceptor substrates - Google Patents
Apparatus and method for coating photoreceptor substrates Download PDFInfo
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- US20030064164A1 US20030064164A1 US09/969,387 US96938701A US2003064164A1 US 20030064164 A1 US20030064164 A1 US 20030064164A1 US 96938701 A US96938701 A US 96938701A US 2003064164 A1 US2003064164 A1 US 2003064164A1
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- rounded objects
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- 239000000758 substrate Substances 0.000 title claims abstract description 50
- 108091008695 photoreceptors Proteins 0.000 title claims abstract description 49
- 238000000576 coating method Methods 0.000 title claims abstract description 43
- 239000011248 coating agent Substances 0.000 title claims abstract description 41
- 238000000034 method Methods 0.000 title claims description 36
- 239000012530 fluid Substances 0.000 claims abstract description 26
- 238000007864 suspending Methods 0.000 claims abstract description 15
- 239000011521 glass Substances 0.000 claims abstract description 7
- 229910001220 stainless steel Inorganic materials 0.000 claims abstract description 5
- 239000010935 stainless steel Substances 0.000 claims abstract description 5
- 229910052751 metal Inorganic materials 0.000 claims description 7
- 239000002184 metal Substances 0.000 claims description 7
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 6
- 229910010293 ceramic material Inorganic materials 0.000 claims description 5
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 3
- 229910052782 aluminium Inorganic materials 0.000 claims description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 3
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 3
- 229910052573 porcelain Inorganic materials 0.000 claims description 3
- 239000010936 titanium Substances 0.000 claims description 3
- 229910052719 titanium Inorganic materials 0.000 claims description 3
- 239000004408 titanium dioxide Substances 0.000 claims description 3
- 239000011324 bead Substances 0.000 abstract description 9
- 230000007547 defect Effects 0.000 abstract description 5
- 230000016615 flocculation Effects 0.000 description 4
- 238000005189 flocculation Methods 0.000 description 4
- 239000000049 pigment Substances 0.000 description 3
- 239000006185 dispersion Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 239000002904 solvent Substances 0.000 description 2
- 239000000725 suspension Substances 0.000 description 2
- 239000011149 active material Substances 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 238000003618 dip coating Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- -1 for example Inorganic materials 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 239000012528 membrane Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05C3/00—Apparatus in which the work is brought into contact with a bulk quantity of liquid or other fluent material
- B05C3/02—Apparatus in which the work is brought into contact with a bulk quantity of liquid or other fluent material the work being immersed in the liquid or other fluent material
- B05C3/09—Apparatus in which the work is brought into contact with a bulk quantity of liquid or other fluent material the work being immersed in the liquid or other fluent material for treating separate articles
- B05C3/109—Passing liquids or other fluent materials into or through chambers containing stationary articles
-
- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03G—ELECTROGRAPHY; ELECTROPHOTOGRAPHY; MAGNETOGRAPHY
- G03G5/00—Recording members for original recording by exposure, e.g. to light, to heat, to electrons; Manufacture thereof; Selection of materials therefor
- G03G5/02—Charge-receiving layers
- G03G5/04—Photoconductive layers; Charge-generation layers or charge-transporting layers; Additives therefor; Binders therefor
- G03G5/05—Organic bonding materials; Methods for coating a substrate with a photoconductive layer; Inert supplements for use in photoconductive layers
- G03G5/0525—Coating methods
Definitions
- This invention relates to coating photoreceptor substrates using dip tanks and more particularly to coating photoreceptor substrates using a dip tank arranged with a plurality of layers of rounded objects or beads.
- a photoreceptor substrate (belt or drum) is immersed or “dipped” into the orifice of a tank containing the solution to be coated and then withdrawn at a rate that controls the coating thickness.
- the usual mechanism to coat the substrate is to pump a coating solution containing the active materials, either dissolved or in suspension (such as pigments), into the tank from an inlet located in the bottom of the diptank and continuously overflow the tank at the orifice located at the top of the tank. In this way the substrate is subjected to a uniform flow of solution relative to the coating speed.
- an apparatus for coating at least one substrate with a fluid comprises at least one diptank defining an inlet and a conduit with an orifice, the conduit including means for suspending a plurality of layers of rounded objects so that fluid supplied to the inlet flows through the plurality of layers of rounded objects to coat a substrate that is inserted through the orifice.
- a method for coating at least one substrate with a fluid uses an apparatus comprising at least one diptank defining an inlet and a conduit with an orifice, the conduit including means for suspending a plurality of layers of rounded objects, so that fluid supplied to the inlet flows through the plurality of layers of rounded objects to coat a substrate that is inserted through the orifice.
- the method comprises supplying fluid to the inlet and inserting at least one substrate through the orifice.
- FIG. 1 depicts an apparatus 100 for coating photoreceptor substrates in accordance with the present invention.
- FIG. 2A depicts a photoreceptor belt substrate 20 A that may be coated by the FIG. 1 apparatus.
- FIG. 2B depicts a photoreceptor drum substrate 20 B that may be coated by the FIG. 1 apparatus.
- FIG. 3A depicts a first porous element 31 of the apparatus 100 .
- FIG. 3B depicts a second porous element 32 of the apparatus 100 .
- FIG. 4 depicts various embodiments of rounded objects or beads 400 that may be used in the apparatus 100 .
- the rounded objects 400 include a spherical-shaped embodiment 401 and an elliptical-shaped embodiment 402 .
- the latter elliptical embodiment 402 also includes other embodiments 402 ′, 402 ′′ and 402 ′′′.
- FIG. 5A depicts the apparatus 100 with two layers of the spherical objects 401 .
- FIG. 5B depicts the apparatus 100 with three layers of the spherical objects 401 .
- FIG. 5C depicts the apparatus 100 with two or more layers of the spherical objects 401 .
- FIG. 6A depicts the apparatus 100 with two layers of the elliptical objects 402 .
- FIG. 6B depicts the apparatus 100 with three layers of the elliptical objects 402 .
- FIG. 6C depicts the apparatus 100 with two or more layers of the elliptical objects 402 .
- FIG. 7A depicts the apparatus 100 with two layers of rounded objects 400 comprising one or more spherical objects 401 and one or more elliptical objects 402 .
- FIG. 7B depicts the apparatus 100 with three layers of rounded objects 400 comprising one or more spherical objects 401 and one or more elliptical objects 402 .
- FIG. 7C depicts the apparatus 100 with two or more layers of rounded objects 400 comprising one or more spherical objects 401 and one or more elliptical objects 402 .
- an apparatus for coating a photoreceptor substrate such as a photoreceptor belt or a photoreceptor drum.
- the apparatus comprises at least one photoreceptor coating fluid reservoir or diptank.
- the diptank defines an inlet at one end and a conduit with an orifice at the other end.
- the conduit includes at least one porous element such as a grid, screen or mesh arranged for suspending a plurality of layers of non-contaminating rounded objects, such as stainless steel or glass beads, in the bottom of the conduit.
- Photoreceptor coating solution supplied to the inlet is thereby forced to flow through the plurality of layers of beads prior to coating a photoreceptor substrate that is inserted through the orifice.
- the uniformity of the coating solution is improved as it coats the photoreceptor substrate, thereby reducing coating defects in the finished photoreceptor belt or drum.
- FIGS. 2 A- 2 B there are shown typical photoreceptor substrates which may be used relative to the present invention.
- FIG. 2A there is shown a flexible photoreceptor belt substrate 20 A and in FIG. 2B there is shown a cylindrical-shaped photoreceptor drum substrate 20 B.
- FIG. 1 there is shown an apparatus 100 for coating at least one of the foregoing substrates 20 A and 20 B with a fluid 200 .
- the fluid 200 comprises photoreceptor coating solution.
- the apparatus 100 comprises at least one diptank 10 .
- the diptank 10 defines an inlet 1 at one end and a conduit 9 with an orifice 11 at the other end.
- the conduit 9 forms a conduit inner diameter 12 .
- the conduit 9 includes means 31 - 32 for suspending a plurality of layers of rounded objects or beads 400 substantially across and thereby covering the conduit inner diameter 12 .
- the plurality of layers of rounded objects 400 are suspended near the bottom 15 of the conduit 9 .
- the plurality of layers of rounded objects 400 are positioned between the inlet 1 and the orifice 11 .
- substantially all of the fluid 200 that is supplied 2 A to the inlet 1 initially is forced to flow 2 B through the plurality of layers of rounded objects 400 before later flowing 2 C towards the orifice 11 , thereby coating a substrate 20 A or 20 B that previously has been inserted or dipped 80 through the orifice 11 .
- the means for suspending the rounded objects 400 comprise only a first, lower, porous element 31 , with the rounded objects 400 being disposed on top of the porous element 31 .
- the means for suspending the rounded objects 400 comprise both the foregoing first, lower, porous element 31 and also a second, upper, porous element 32 , with the rounded objects 400 being disposed between the first porous element 31 and the second porous element 32 .
- the first porous element 31 has a plurality of apertures 301 dispersed throughout.
- the second porous element 32 likewise has a plurality of apertures 302 dispersed throughout.
- either or both of the porous elements 31 and 32 comprise a grid, screen or mesh.
- either or both of the porous elements 31 and 32 are similar to the porous membrane 30 of the foregoing U.S. Pat. No. 5,681,392.
- either or both of the porous elements 31 and 32 are similar to the perforated plate 40 of the foregoing U.S. Pat. No. 5,681,392.
- the rounded objects 400 comprise spherical-shaped objects, such as the depicted spherical object 401 ; elliptical-shaped objects, such as the depicted elliptical objects 402 ; and a mixture of spherical objects 401 and elliptical objects 402 .
- the depicted elliptical-shaped object 402 includes variations thereof, including the depicted elliptical object embodiments 402 ′, 402 ′′ and 402 ′′′. While only the elliptical embodiments 402 ′, 402 ′′ and 402 ′′′ are shown, it will be understood that still other embodiments of the elliptical-shaped object 402 are possible.
- the rounded objects 400 of the present invention including the foregoing spherical object 401 and the elliptical object 402 (including the elliptical embodiments 402 ′, 402 ′′ and 402 ′′′), have a smooth surface, are non-contaminating, with diameters varying from 10 to 30 millimeters. It will be understood that the rounded objects 400 are commonly known as “beads”.
- the rounded objects 400 are generally comprised of glass.
- the rounded objects 400 are generally comprised of a ceramic material such as, for example, porcelain, aluminum oxide, titanium dioxide, or equivalents thereof.
- the rounded objects 400 are generally comprised of metal such as, for example, aluminum, stainless steel or titanium.
- the apparatus 100 comprises a plurality of layers of rounded objects 400 wherein substantially all of the rounded objects 400 are comprised of a single (1) material, such as glass, ceramic, or metal.
- the apparatus 100 comprises a plurality of layers of rounded objects 400 comprised of more than one (1) material.
- a hypothetical apparatus 100 might comprise a plurality of layers of rounded objects 400 wherein 50% of the rounded objects 400 are comprised of glass, and the remaining 50% of the rounded objects 400 are comprised of metal.
- the apparatus 100 comprises a plurality of layers of rounded objects 400 wherein substantially all of the rounded objects 400 are comprised of similar dimensions or diameters.
- the apparatus 100 comprises a plurality of layers of rounded objects 400 comprised of different or varying dimensions.
- a hypothetical apparatus 100 might comprise a plurality of layers of rounded objects 400 wherein 35% of the rounded objects 400 have diameters of 10 millimeters, and the remaining 65% of the rounded objects 400 have diameters of 20 millimeters.
- FIGS. 5 - 7 there is depicted various embodiments of the apparatus 100 comprising a plurality of layers of rounded objects 400 suspended in the conduit 9 by the suspending means 31 - 32 , as depicted in FIG. 1.
- FIGS. 5 - 7 are briefly summarized as follows:
- FIG. 5 depicts various embodiments of the apparatus 100 wherein the plurality of layers of rounded objects 400 generally comprise the spherical objects 401 .
- FIG. 6 depicts various embodiments of the apparatus 100 wherein the plurality of layers of rounded objects 400 generally comprise the elliptical objects 402 .
- FIG. 7 depicts various embodiments of the apparatus 100 wherein the plurality of layers of rounded objects 400 comprise one or more spherical objects 401 and one or more elliptical objects 402 .
- FIG. 5A there is depicted one embodiment of the apparatus 100 wherein the plurality of layers of rounded objects 400 comprise two (2) layers of the spherical objects 401 .
- FIG. 5B there is depicted another embodiment of the apparatus 100 wherein the plurality of layers of rounded objects 400 comprise three (3) layers of the spherical objects 401 .
- FIG. 5C there is depicted still another embodiment of the apparatus 100 wherein the plurality of layers of rounded objects 400 comprise two or more (i.e., 2 , 3 , 4 , 5 , or a still greater number, etc.) layers of the spherical objects 401 .
- FIG. 6 comprising three separate views respectively designated FIGS. 6A, 6B and 6 C.
- FIG. 6A there is depicted one embodiment of the apparatus 100 wherein the plurality of layers of rounded objects 400 comprise two (2) layers of the elliptical objects 402 .
- substantially all such elliptical objects 402 are comprised of an identical elliptical shape, such as, for example, only one of the elliptical object embodiments 402 ′, 402 ′′ and 402 ′′′ depicted in FIG. 4.
- FIG. 6A there is depicted one embodiment of the apparatus 100 wherein the plurality of layers of rounded objects 400 comprise two (2) layers of the elliptical objects 402 .
- substantially all such elliptical objects 402 are comprised of an identical elliptical shape, such as, for example, only one of the elliptical object embodiments 402 ′, 402 ′′ and 402 ′′′ depicted in FIG. 4.
- FIG. 4 In another contrasting embodiment of FIG.
- such elliptical objects 402 are comprised of different elliptical shapes, such as, for example, at least two of the elliptical object embodiments 402 ′, 402 ′′ and 402 ′′′ depicted in FIG. 4.
- FIG. 6B there is depicted another embodiment of the apparatus 100 wherein the plurality of layers of rounded objects 400 comprise three (3) layers of the elliptical objects 402 .
- substantially all such elliptical objects 402 are comprised of an identical elliptical shape, such as, for example, only one of the elliptical object embodiments 402 ′, 402 ′′ and 402 ′′′ depicted in FIG. 4.
- FIG. 6B there is depicted another embodiment of the apparatus 100 wherein the plurality of layers of rounded objects 400 comprise three (3) layers of the elliptical objects 402 .
- substantially all such elliptical objects 402 are comprised of an identical elliptical shape, such as, for example, only one of the elliptical object embodiments 402 ′, 402 ′′ and 402 ′′′ depicted in FIG. 4.
- FIG. 4 In another contrasting embodiment of FIG.
- such elliptical objects 402 are comprised of different elliptical shapes, such as, for example, at least two of the elliptical object embodiments 402 ′, 402 ′′ and 402 ′′′ depicted in FIG. 4.
- FIG. 6C there is depicted still another embodiment of the apparatus 100 wherein the plurality of layers of rounded objects 400 comprise two or more (i.e., 2 , 3 , 4 , 5 , or a still greater number, etc.) layers of the elliptical objects 402 .
- substantially all such elliptical objects 402 are comprised of an identical elliptical shape, such as, for example, only one of the elliptical object embodiments 402 ′, 402 ′′ and 402 ′′′ depicted in FIG. 4.
- FIG. 6C there is depicted still another embodiment of the apparatus 100 wherein the plurality of layers of rounded objects 400 comprise two or more (i.e., 2 , 3 , 4 , 5 , or a still greater number, etc.) layers of the elliptical objects 402 .
- substantially all such elliptical objects 402 are comprised of an identical elliptical shape, such as, for example, only one of the ellipt
- such elliptical objects 402 are comprised of different elliptical shapes, such as, for example, at least two of the elliptical object embodiments 402 ′, 402 ′′ and 402 ′′′ depicted in FIG. 4.
- FIG. 7 comprising three separate views respectively designated FIGS. 7A, 7B and 7 C.
- FIG. 7A there is depicted one embodiment of the apparatus 100 wherein the plurality of layers of rounded objects 400 comprise two (2) layers of rounded objects 400 comprising one or more spherical objects 401 and one or more elliptical objects 402 .
- the two (2) layers of rounded objects 400 comprise a fixed or predetermined combination or arrangement of one or more spherical objects 401 and one or more elliptical objects 402 .
- the two (2) layers of rounded objects 400 comprise an arbitrary or random combination or arrangement of one or more spherical objects 401 and one or more elliptical objects 402 .
- the two (2) layers of rounded objects 400 comprise only one (1) spherical object 401 .
- the two (2) layers of rounded objects 400 comprise only one (1) elliptical object 402 .
- FIG. 7B there is depicted another embodiment of the apparatus 100 wherein the plurality of layers of rounded objects 400 comprise three (3) layers of rounded objects 400 comprising one or more spherical objects 401 and one or more elliptical objects 402 .
- the three (2) layers of rounded objects 400 comprise a fixed or predetermined combination or arrangement of one or more spherical objects 401 and one or more elliptical objects 402 .
- the three (2) layers of rounded objects 400 comprise an arbitrary or random combination or arrangement of one or more spherical objects 401 and one or more elliptical objects 402 .
- the three (3) layers of rounded objects 400 comprise only one (1) spherical object 401 .
- the three (3) layers of rounded objects 400 comprise only one (1) elliptical object 402 .
- FIG. 7C there is depicted still another embodiment of the apparatus 100 wherein the plurality of layers of rounded objects 400 comprise two (2) or more (i.e., 2 , 3 , 4 , 5 , or a still greater number, etc.) layers of rounded objects 400 comprising one or more spherical objects 401 and one or more elliptical objects 402 .
- the two (2) or more layers of rounded objects 400 comprise a fixed or predetermined combination or arrangement of one or more spherical objects 401 and one or more elliptical objects 402 .
- FIG. 7C there is depicted still another embodiment of the apparatus 100 wherein the plurality of layers of rounded objects 400 comprise two (2) or more (i.e., 2 , 3 , 4 , 5 , or a still greater number, etc.) layers of rounded objects 400 comprising one or more spherical objects 401 and one or more elliptical objects 402 .
- the two (2) or more layers of rounded objects 400 comprise
- the two (2) or more layers of rounded objects 400 comprise an arbitrary or random combination or arrangement of one or more spherical objects 401 and one or more elliptical objects 402 .
- the two (2) or more layers of rounded objects 400 comprise only one (1) spherical object 401 .
- the two (2) or more layers of rounded objects 400 comprise only one (1) elliptical object 402 .
- the apparatus 100 comprising at least one diptank 10 defining an inlet 1 and a conduit 9 with an orifice 11 , the conduit 9 including means 31 - 32 for suspending a plurality of layers of rounded objects 400 , so that fluid 200 supplied 2 A to the inlet 1 flows 2 B through the plurality of layers of rounded objects 400 to coat 2 C a substrate that is inserted 80 through the orifice 11 , the method comprising supplying 2 A fluid to the inlet 1 and inserting 80 at least one substrate through the orifice 11 .
- the at least one substrate comprises a photoreceptor substrate 20 A or 20 B and the fluid 200 comprising photoreceptor coating solution.
- this invention suspends plural layers of noncontaminating rounded objects, commonly known as “beads”, between suspension devices such as mesh screens. These layers of rounded objects are then placed in the bottom of the dip tank. As a result, the photoreceptor substrate coating process becomes more uniform, which reduces coating defects in the resulting finished photoreceptor belts or drums.
- one possible theory of operation is that the layers of rounded objects create additional shear in the solution as it is being pumped into the tank.
- the increased shear in the solution reduces flocculation, reduces solvent-rich and pigment-rich zones in the tank, disperses the flow in the tank, and eliminates stagnant zones which trap contaminants.
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Abstract
Description
- The disclosure of commonly-assigned U.S. Pat. No. 5,681,392 by Eugene A. Swain, entitled “Fluid reservoir containing panels for reducing rate of fluid flow,” issued Oct. 28, 1997 is hereby incorporated by reference in this application verbatim, with the same effect as though such disclosure were fully and completely set forth herein. It is noted that the same Eugene A. Swain is a named inventor both in the foregoing U.S. patent and in the present application.
- This invention relates to coating photoreceptor substrates using dip tanks and more particularly to coating photoreceptor substrates using a dip tank arranged with a plurality of layers of rounded objects or beads.
- It is known to use coating fluid reservoirs or “diptanks” to apply photoreceptor coating solution to coat photoreceptor devices such as photoreceptor flexible belts and cylindrical-shaped drums. In the foregoing U.S. Pat. No. 5,681,392 to Eugene A. Swain, for example, the fluid reservoir (equivalent to a diptank)10 is used to supply organic
photoreceptor coating fluid 80 to coat a flexible belt-type photoreceptor substrate 60. - In this coating process, a photoreceptor substrate (belt or drum) is immersed or “dipped” into the orifice of a tank containing the solution to be coated and then withdrawn at a rate that controls the coating thickness. The usual mechanism to coat the substrate is to pump a coating solution containing the active materials, either dissolved or in suspension (such as pigments), into the tank from an inlet located in the bottom of the diptank and continuously overflow the tank at the orifice located at the top of the tank. In this way the substrate is subjected to a uniform flow of solution relative to the coating speed.
- There are several disadvantages to the dip coating process which can result in defects on the coated substrate surface.
- For example, typically there is very little radial surface velocity of the coating solution at the top of the tank. In fact, usually there is a conical volume in the tank where there is relatively little coating solution flow. As a result of non-uniformities in the coating solution, coating streaks can occur along part or all of the dipped length of the photoreceptor substrate. Such non-uniformities can occur especially from dispersions that have poor stability and display a property of non-uniform dispersion distribution called flocculation.
- As is known, flocculation occurs when there is little or no movement or shear of the solution, such as the conical volume of the tank discussed above. Flocculation results in solvent-rich and pigment-rich zones in the dip tank. Unfortunately, such zones are exactly where the photoreceptor substrate is immersed. Ultimately, these phenomena can result in coating streaks or other defects in the resulting finished photoreceptor device.
- As a result, there is a need for an improved apparatus and method for coating photoreceptor substrates.
- In one aspect of the invention, there is provided an apparatus for coating at least one substrate with a fluid. The apparatus comprises at least one diptank defining an inlet and a conduit with an orifice, the conduit including means for suspending a plurality of layers of rounded objects so that fluid supplied to the inlet flows through the plurality of layers of rounded objects to coat a substrate that is inserted through the orifice.
- In another aspect of the invention, there is provided a method for coating at least one substrate with a fluid. The method uses an apparatus comprising at least one diptank defining an inlet and a conduit with an orifice, the conduit including means for suspending a plurality of layers of rounded objects, so that fluid supplied to the inlet flows through the plurality of layers of rounded objects to coat a substrate that is inserted through the orifice. The method comprises supplying fluid to the inlet and inserting at least one substrate through the orifice.
- FIG. 1 depicts an
apparatus 100 for coating photoreceptor substrates in accordance with the present invention. - FIG. 2A depicts a
photoreceptor belt substrate 20A that may be coated by the FIG. 1 apparatus. - FIG. 2B depicts a
photoreceptor drum substrate 20B that may be coated by the FIG. 1 apparatus. - FIG. 3A depicts a first
porous element 31 of theapparatus 100. - FIG. 3B depicts a second
porous element 32 of theapparatus 100. - FIG. 4 depicts various embodiments of rounded objects or
beads 400 that may be used in theapparatus 100. As shown, therounded objects 400 include a spherical-shaped embodiment 401 and an elliptical-shaped embodiment 402. As shown, the latterelliptical embodiment 402 also includesother embodiments 402′, 402″ and 402′″. - FIG. 5A depicts the
apparatus 100 with two layers of thespherical objects 401. - FIG. 5B depicts the
apparatus 100 with three layers of thespherical objects 401. - FIG. 5C depicts the
apparatus 100 with two or more layers of thespherical objects 401. - FIG. 6A depicts the
apparatus 100 with two layers of theelliptical objects 402. - FIG. 6B depicts the
apparatus 100 with three layers of theelliptical objects 402. - FIG. 6C depicts the
apparatus 100 with two or more layers of theelliptical objects 402. - FIG. 7A depicts the
apparatus 100 with two layers ofrounded objects 400 comprising one or morespherical objects 401 and one or moreelliptical objects 402. - FIG. 7B depicts the
apparatus 100 with three layers ofrounded objects 400 comprising one or morespherical objects 401 and one or moreelliptical objects 402. - FIG. 7C depicts the
apparatus 100 with two or more layers ofrounded objects 400 comprising one or morespherical objects 401 and one or moreelliptical objects 402. - Briefly, there is disclosed an apparatus for coating a photoreceptor substrate, such as a photoreceptor belt or a photoreceptor drum. The apparatus comprises at least one photoreceptor coating fluid reservoir or diptank. The diptank defines an inlet at one end and a conduit with an orifice at the other end. The conduit includes at least one porous element such as a grid, screen or mesh arranged for suspending a plurality of layers of non-contaminating rounded objects, such as stainless steel or glass beads, in the bottom of the conduit. Photoreceptor coating solution supplied to the inlet is thereby forced to flow through the plurality of layers of beads prior to coating a photoreceptor substrate that is inserted through the orifice. As a result, the uniformity of the coating solution is improved as it coats the photoreceptor substrate, thereby reducing coating defects in the finished photoreceptor belt or drum.
- Referring now generally to FIGS.2A-2B, there are shown typical photoreceptor substrates which may be used relative to the present invention. For example, in FIG. 2A there is shown a flexible
photoreceptor belt substrate 20A and in FIG. 2B there is shown a cylindrical-shapedphotoreceptor drum substrate 20B. - Referring now to FIG. 1, there is shown an
apparatus 100 for coating at least one of the foregoingsubstrates fluid 200. In one embodiment, the fluid 200 comprises photoreceptor coating solution. - As shown in FIG. 1, the
apparatus 100 comprises at least onediptank 10. Thediptank 10 defines aninlet 1 at one end and aconduit 9 with anorifice 11 at the other end. In turn, theconduit 9 forms a conduitinner diameter 12. As discussed in greater detail below, theconduit 9 includes means 31-32 for suspending a plurality of layers of rounded objects orbeads 400 substantially across and thereby covering the conduitinner diameter 12. As shown, the plurality of layers ofrounded objects 400 are suspended near the bottom 15 of theconduit 9. Thus suspended, the plurality of layers ofrounded objects 400 are positioned between theinlet 1 and theorifice 11. Moreover, as a result of such position, substantially all of the fluid 200 that is supplied 2A to theinlet 1 initially is forced to flow 2B through the plurality of layers ofrounded objects 400 before later flowing 2C towards theorifice 11, thereby coating asubstrate orifice 11. - Still referring to FIG. 1, in one embodiment, the means for suspending the
rounded objects 400 comprise only a first, lower,porous element 31, with therounded objects 400 being disposed on top of theporous element 31. In another embodiment, the means for suspending therounded objects 400 comprise both the foregoing first, lower,porous element 31 and also a second, upper,porous element 32, with therounded objects 400 being disposed between the firstporous element 31 and the secondporous element 32. - Turning now to FIG. 3A, it is seen that the first
porous element 31 has a plurality ofapertures 301 dispersed throughout. As well, turning now to FIG. 3B, it is seen the secondporous element 32 likewise has a plurality ofapertures 302 dispersed throughout. - In one embodiment, either or both of the
porous elements - In another embodiment, either or both of the
porous elements - In still another embodiment, either or both of the
porous elements - Referring now to FIG. 4, there are shown various embodiments of the FIG. 1 rounded
objects 400. As shown, therounded objects 400 comprise spherical-shaped objects, such as the depictedspherical object 401; elliptical-shaped objects, such as the depictedelliptical objects 402; and a mixture ofspherical objects 401 andelliptical objects 402. - Referring still to FIG. 4, it will be understood the depicted elliptical-shaped
object 402 includes variations thereof, including the depictedelliptical object embodiments 402′, 402″ and 402′″. While only theelliptical embodiments 402′, 402″ and 402′″ are shown, it will be understood that still other embodiments of the elliptical-shapedobject 402 are possible. - Still referring to FIG. 4, the
rounded objects 400 of the present invention, including the foregoingspherical object 401 and the elliptical object 402 (including theelliptical embodiments 402′, 402″ and 402′″), have a smooth surface, are non-contaminating, with diameters varying from 10 to 30 millimeters. It will be understood that therounded objects 400 are commonly known as “beads”. - In one embodiment, the
rounded objects 400 are generally comprised of glass. - In another embodiment, the
rounded objects 400 are generally comprised of a ceramic material such as, for example, porcelain, aluminum oxide, titanium dioxide, or equivalents thereof. - In still another embodiment, the
rounded objects 400 are generally comprised of metal such as, for example, aluminum, stainless steel or titanium. - Returning momentarily to FIG. 1, in one embodiment the
apparatus 100 comprises a plurality of layers ofrounded objects 400 wherein substantially all of therounded objects 400 are comprised of a single (1) material, such as glass, ceramic, or metal. In contrast, in another embodiment, theapparatus 100 comprises a plurality of layers ofrounded objects 400 comprised of more than one (1) material. As an example of this latter contrasting embodiment, for example, ahypothetical apparatus 100 might comprise a plurality of layers ofrounded objects 400 wherein 50% of therounded objects 400 are comprised of glass, and the remaining 50% of therounded objects 400 are comprised of metal. - Still referring to FIG. 1, in one embodiment the
apparatus 100 comprises a plurality of layers ofrounded objects 400 wherein substantially all of therounded objects 400 are comprised of similar dimensions or diameters. In contrast, in another embodiment, theapparatus 100 comprises a plurality of layers ofrounded objects 400 comprised of different or varying dimensions. As an example of this latter contrasting embodiment, for example, ahypothetical apparatus 100 might comprise a plurality of layers ofrounded objects 400 wherein 35% of therounded objects 400 have diameters of 10 millimeters, and the remaining 65% of therounded objects 400 have diameters of 20 millimeters. - Referring now generally to FIGS.5-7, there is depicted various embodiments of the
apparatus 100 comprising a plurality of layers ofrounded objects 400 suspended in theconduit 9 by the suspending means 31-32, as depicted in FIG. 1. - FIGS.5-7 are briefly summarized as follows:
- FIG. 5 depicts various embodiments of the
apparatus 100 wherein the plurality of layers ofrounded objects 400 generally comprise thespherical objects 401. - FIG. 6 depicts various embodiments of the
apparatus 100 wherein the plurality of layers ofrounded objects 400 generally comprise theelliptical objects 402. - FIG. 7 depicts various embodiments of the
apparatus 100 wherein the plurality of layers ofrounded objects 400 comprise one or morespherical objects 401 and one or moreelliptical objects 402. - Refer now to FIG. 5, comprising three separate views respectively designated FIGS. 5A, 5B and5C. In FIG. 5A there is depicted one embodiment of the
apparatus 100 wherein the plurality of layers ofrounded objects 400 comprise two (2) layers of thespherical objects 401. In FIG. 5B there is depicted another embodiment of theapparatus 100 wherein the plurality of layers ofrounded objects 400 comprise three (3) layers of thespherical objects 401. In FIG. 5C there is depicted still another embodiment of theapparatus 100 wherein the plurality of layers ofrounded objects 400 comprise two or more (i.e., 2, 3, 4, 5, or a still greater number, etc.) layers of thespherical objects 401. - Refer now to FIG. 6, comprising three separate views respectively designated FIGS. 6A, 6B and6C.
- In FIG. 6A there is depicted one embodiment of the
apparatus 100 wherein the plurality of layers ofrounded objects 400 comprise two (2) layers of theelliptical objects 402. In one embodiment of FIG. 6A, substantially all suchelliptical objects 402 are comprised of an identical elliptical shape, such as, for example, only one of theelliptical object embodiments 402′, 402″ and 402′″ depicted in FIG. 4. In another contrasting embodiment of FIG. 6A, suchelliptical objects 402 are comprised of different elliptical shapes, such as, for example, at least two of theelliptical object embodiments 402′, 402″ and 402′″ depicted in FIG. 4. - In FIG. 6B there is depicted another embodiment of the
apparatus 100 wherein the plurality of layers ofrounded objects 400 comprise three (3) layers of theelliptical objects 402. In one embodiment of FIG. 6B, substantially all suchelliptical objects 402 are comprised of an identical elliptical shape, such as, for example, only one of theelliptical object embodiments 402′, 402″ and 402′″ depicted in FIG. 4. In another contrasting embodiment of FIG. 6B, suchelliptical objects 402 are comprised of different elliptical shapes, such as, for example, at least two of theelliptical object embodiments 402′, 402″ and 402′″ depicted in FIG. 4. - In FIG. 6C there is depicted still another embodiment of the
apparatus 100 wherein the plurality of layers ofrounded objects 400 comprise two or more (i.e., 2, 3, 4, 5, or a still greater number, etc.) layers of theelliptical objects 402. In one embodiment of FIG. 6C, substantially all suchelliptical objects 402 are comprised of an identical elliptical shape, such as, for example, only one of theelliptical object embodiments 402′, 402″ and 402′″ depicted in FIG. 4. In another contrasting embodiment of FIG. 6C, suchelliptical objects 402 are comprised of different elliptical shapes, such as, for example, at least two of theelliptical object embodiments 402′, 402″ and 402′″ depicted in FIG. 4. - Refer now to FIG. 7, comprising three separate views respectively designated FIGS. 7A, 7B and7C.
- In FIG. 7A there is depicted one embodiment of the
apparatus 100 wherein the plurality of layers ofrounded objects 400 comprise two (2) layers ofrounded objects 400 comprising one or morespherical objects 401 and one or moreelliptical objects 402. In one embodiment of FIG. 7A, the two (2) layers ofrounded objects 400 comprise a fixed or predetermined combination or arrangement of one or morespherical objects 401 and one or moreelliptical objects 402. In another embodiment of FIG. 7A, the two (2) layers ofrounded objects 400 comprise an arbitrary or random combination or arrangement of one or morespherical objects 401 and one or moreelliptical objects 402. In a further embodiment of FIG. 7A, the two (2) layers ofrounded objects 400 comprise only one (1)spherical object 401. In a still further embodiment of FIG. 7A, the two (2) layers ofrounded objects 400 comprise only one (1)elliptical object 402. - In FIG. 7B there is depicted another embodiment of the
apparatus 100 wherein the plurality of layers ofrounded objects 400 comprise three (3) layers ofrounded objects 400 comprising one or morespherical objects 401 and one or moreelliptical objects 402. In one embodiment of FIG. 7B, the three (2) layers ofrounded objects 400 comprise a fixed or predetermined combination or arrangement of one or morespherical objects 401 and one or moreelliptical objects 402. In another embodiment of FIG. 7B, the three (2) layers ofrounded objects 400 comprise an arbitrary or random combination or arrangement of one or morespherical objects 401 and one or moreelliptical objects 402. In a further embodiment of FIG. 7B, the three (3) layers ofrounded objects 400 comprise only one (1)spherical object 401. In a still further embodiment of FIG. 7B, the three (3) layers ofrounded objects 400 comprise only one (1)elliptical object 402. - In FIG. 7C there is depicted still another embodiment of the
apparatus 100 wherein the plurality of layers ofrounded objects 400 comprise two (2) or more (i.e., 2, 3, 4, 5, or a still greater number, etc.) layers ofrounded objects 400 comprising one or morespherical objects 401 and one or moreelliptical objects 402. In one embodiment of FIG. 7C, the two (2) or more layers ofrounded objects 400 comprise a fixed or predetermined combination or arrangement of one or morespherical objects 401 and one or moreelliptical objects 402. In another embodiment of FIG. 7C, the two (2) or more layers ofrounded objects 400 comprise an arbitrary or random combination or arrangement of one or morespherical objects 401 and one or moreelliptical objects 402. In a further embodiment of FIG. 7C, the two (2) or more layers ofrounded objects 400 comprise only one (1)spherical object 401. In a still further embodiment of FIG. 7C, the two (2) or more layers ofrounded objects 400 comprise only one (1)elliptical object 402. - In addition to disclosing the
apparatus 100 depicted in FIG. 1 and described hereinabove, it will be understood that there has also been disclosed a method. - In particular, there has been disclosed a method for coating at least one substrate with a fluid200 using the
apparatus 100, theapparatus 100 comprising at least onediptank 10 defining aninlet 1 and aconduit 9 with anorifice 11, theconduit 9 including means 31-32 for suspending a plurality of layers ofrounded objects 400, so thatfluid 200 supplied 2A to theinlet 1flows 2B through the plurality of layers ofrounded objects 400 tocoat 2C a substrate that is inserted 80 through theorifice 11, the method comprising supplying 2A fluid to theinlet 1 and inserting 80 at least one substrate through theorifice 11. - Moreover, in one embodiment of the foregoing method, it will be understood that the at least one substrate comprises a
photoreceptor substrate - In summary, this invention suspends plural layers of noncontaminating rounded objects, commonly known as “beads”, between suspension devices such as mesh screens. These layers of rounded objects are then placed in the bottom of the dip tank. As a result, the photoreceptor substrate coating process becomes more uniform, which reduces coating defects in the resulting finished photoreceptor belts or drums.
- While not essential to practicing the invention, one possible theory of operation is that the layers of rounded objects create additional shear in the solution as it is being pumped into the tank. According to this theory, the increased shear in the solution reduces flocculation, reduces solvent-rich and pigment-rich zones in the tank, disperses the flow in the tank, and eliminates stagnant zones which trap contaminants.
- While various embodiments of an apparatus and method for coating photoreceptor substrates, in accordance with the invention, have been described hereinabove, the scope of the invention is defined by the following claims.
Claims (50)
Priority Applications (7)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/969,387 US6569499B2 (en) | 2001-10-02 | 2001-10-02 | Apparatus and method for coating photoreceptor substrates |
JP2002278277A JP2003154299A (en) | 2001-10-02 | 2002-09-25 | Apparatus for coating base material with liquid |
BRPI0203987-7A BR0203987B1 (en) | 2001-10-02 | 2002-10-01 | method for coating at least one substrate with a fluid using an apparatus. |
DE60218797T DE60218797T2 (en) | 2001-10-02 | 2002-10-02 | Apparatus and method for coating photosensitive substrate |
EP02022107A EP1300197B1 (en) | 2001-10-02 | 2002-10-02 | Apparatus and method for coating photoreceptor substrates |
US10/287,754 US6746538B2 (en) | 2001-10-02 | 2002-11-01 | Apparatus and method for coating photoreceptor substrates |
US11/438,405 US20060208768A1 (en) | 2001-10-02 | 2006-05-22 | High speed peak amplitude comparator |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US09/969,387 US6569499B2 (en) | 2001-10-02 | 2001-10-02 | Apparatus and method for coating photoreceptor substrates |
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US10/287,754 Division US6746538B2 (en) | 2001-10-02 | 2002-11-01 | Apparatus and method for coating photoreceptor substrates |
US11/031,102 Continuation US7049856B2 (en) | 2001-10-01 | 2005-01-06 | High speed peak amplitude comparator |
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US20030064164A1 true US20030064164A1 (en) | 2003-04-03 |
US6569499B2 US6569499B2 (en) | 2003-05-27 |
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US09/969,387 Expired - Lifetime US6569499B2 (en) | 2001-10-02 | 2001-10-02 | Apparatus and method for coating photoreceptor substrates |
US10/287,754 Expired - Fee Related US6746538B2 (en) | 2001-10-02 | 2002-11-01 | Apparatus and method for coating photoreceptor substrates |
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US10/287,754 Expired - Fee Related US6746538B2 (en) | 2001-10-02 | 2002-11-01 | Apparatus and method for coating photoreceptor substrates |
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EP4252922A1 (en) * | 2022-03-29 | 2023-10-04 | Carl Zeiss Vision International GmbH | Lacquer basin, method for dip coating an ophthalmic lens, coating device and ophthalmic lens |
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ES2265452T3 (en) * | 2000-12-21 | 2007-02-16 | Vertex Pharmaceuticals Incorporated | PIRAZOL COMPOUNDS USED AS INHIBITORS OF PROTEIN QUINASA. |
MY141867A (en) | 2002-06-20 | 2010-07-16 | Vertex Pharma | Substituted pyrimidines useful as protein kinase inhibitors |
US6767405B2 (en) | 2002-07-10 | 2004-07-27 | Carmeda Ab | Apparatus and process for coating articles |
AR056763A1 (en) * | 2005-11-03 | 2007-10-24 | Vertex Pharma | AMINOPIRIMIDINES REPLACED WITH TIAZOL OR PIRAZOL, USEFUL AS ANTICANCER AGENTS AND PHARMACEUTICAL COMPOSITIONS CONTAINING THEM. |
JP4568674B2 (en) * | 2005-11-07 | 2010-10-27 | 株式会社リコー | Electrophotographic photoreceptor manufacturing apparatus and manufacturing method |
MX2009009590A (en) * | 2007-03-09 | 2009-11-10 | Vertex Pharma | Aminopyrimidines useful as inhibitors of protein kinases. |
WO2008112646A1 (en) * | 2007-03-09 | 2008-09-18 | Vertex Pharmaceuticals Incorporated | Aminopyridines useful as inhibitors of protein kinases |
CA2694381A1 (en) * | 2007-05-02 | 2008-11-13 | Vertex Pharmaceuticals Incorporated | Aminopyrimidines useful as kinase inhibitors |
CA2685876A1 (en) * | 2007-05-02 | 2008-11-13 | Vertex Pharmaceuticals Incorporated | Thiazoles and pyrazoles useful as kinase inhibitors |
EP2323622A1 (en) * | 2008-09-03 | 2011-05-25 | Vertex Pharmaceuticals Incorporated | Co-crystals and pharmaceutical formulations comprising the same |
JP2014014740A (en) * | 2012-07-06 | 2014-01-30 | Sharp Corp | Surface treatment device |
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US3178308A (en) * | 1960-09-07 | 1965-04-13 | Pfaudler Permutit Inc | Chemical vapor plating process |
CA1164632A (en) * | 1981-10-19 | 1984-04-03 | Jorg-Hein Walling | Fluidizable bed structure |
US5681392A (en) | 1995-12-21 | 1997-10-28 | Xerox Corporation | Fluid reservoir containing panels for reducing rate of fluid flow |
US5693372A (en) * | 1996-02-29 | 1997-12-02 | Xerox Corporation | Immersion coating process |
US5616365A (en) * | 1996-06-10 | 1997-04-01 | Xerox Corporation | Coating method using an inclined surface |
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2001
- 2001-10-02 US US09/969,387 patent/US6569499B2/en not_active Expired - Lifetime
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- 2002-09-25 JP JP2002278277A patent/JP2003154299A/en active Pending
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Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP4252922A1 (en) * | 2022-03-29 | 2023-10-04 | Carl Zeiss Vision International GmbH | Lacquer basin, method for dip coating an ophthalmic lens, coating device and ophthalmic lens |
WO2023186673A1 (en) | 2022-03-29 | 2023-10-05 | Carl Zeiss Vision International Gmbh | Lacquer basin, method for dip coating an ophthalmic lens, coating device and ophthalmic lens |
EP4360766A2 (en) | 2022-03-29 | 2024-05-01 | Carl Zeiss Vision International GmbH | Lacquer basin, method for dip coating an ophthalmic lens, coating device and ophthalmic lens |
Also Published As
Publication number | Publication date |
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DE60218797T2 (en) | 2007-06-28 |
BR0203987A (en) | 2003-09-16 |
EP1300197A3 (en) | 2005-11-16 |
JP2003154299A (en) | 2003-05-27 |
DE60218797D1 (en) | 2007-04-26 |
US6746538B2 (en) | 2004-06-08 |
EP1300197A2 (en) | 2003-04-09 |
US6569499B2 (en) | 2003-05-27 |
US20030064166A1 (en) | 2003-04-03 |
EP1300197B1 (en) | 2007-03-14 |
BR0203987B1 (en) | 2010-09-21 |
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